Pile fabric



Oct, 26, 1948. D. M. COOPER y 2,452,104

.PILE FABRIC F'iled Nov. 28, 1945 2 sheets-sheet 1 s @IE- e @lg gll l-- mm l @L a [VQ al a e f Figa.

Get. 26, 1948. D. M. cooPi-:R 2,452,104

PILE FABRIC Filed Nov. 28, 1945 2 Sheets-Sheet 2 Patented Oct. 26, 1948 UNITED STATES FFICE Application November 28, 1945, Serial No. 631,431 In Great Britain December 2, 1944 9 Claims.

My invention in or relating to the manufacture of pile fabrics has particular reference to those of the class in which the pile is formed by the breakage of weft oats in the raising portion of the process of finishing the fabrics.

The invention has for its object to lprovide, in a fabric of this kind, an improved construction in which increased strength and compactness will be obtained, whilst the back of the fabric will be more level or smooth than hitherto, and the use of more weft pile material for the face of the fabic be permitted, a further object being to enable the fabric to be made, if desired, of lighter weight than hitherto and thus to be more suitable for use in the manufacture of garments for womens wear, and permit of diiferent col cured grounds to be used for back and face without either back or face being affected by the other side.

A fabric according to the invention consists of two distinct warps and three wefts, one weft being interwoven wholly or mainly with one of the warps to form the face of the fabric, a second weft being interwoven wholly or mainly with the other warp to form the back of the fabric, whilst the third weft is employed wholly or mainly to bind the two warps together. If desired, the weft which is employed wholly or mainly to form the face of the fabric may be interwoven at in tervals with the warp which is employed in the formation of the back of the fabric, in which case the weft referred t as being employed to bind the warps together may be interwoven solely with the warp employed to form the face of the fabric. In another modification two of the wefts may be interwoven wholly or mainly with the warp utilised to form the face of the fabric and the third weft be utilised to form with the other warp the back of the fabric and be also utilised to bind the two warps together.

In the accompanying drawings,

Fig. 1 is a plan view showing the first five picks of a preferred construction of the improved fabric;

Fig. 2 is a sectional View showing the interlac ing of the first live picks as woven;

Fig. 3 is a similar View to Fig. 2, but showing the fabric in a partly finished state;

Fig. 4 is afplan view of a portion of the fabric shown in the preceding gures, the showing being on a somewhat smaller scale;

Fig. 5 is a section showing the interlacing of the two lowermost warp ends in Fig. 4;

Figs. 6, 7. and 8 show modifications which may bey made in the construction of the fabric whilst Y two distinct warps, which we term respectively the face and back warps, c represents weft referred to as the face weft, d a weft referred to as the centre weft, and e a weft referred to as the back weft. As will be seen from Fig. 1, the preferred construction of the fabric employs the wefts in the order of two picks of the face weft c, one pick of the centre weft d, and two picks of the back weft e. i

As will also be seen from the drawings, the face weft c interweaves only with the face warp c whilst the centre and back wefts d and c interweave with both the face warp a and the back warp b.

The two picks of face weft c interweave with the face warp a in twill or other formation, and in the illustrated example in twill formation to form weft floats c of suitable length according to the length of pile it is desired to provide. The pick of centre weft d serves to bind the face warp a to the back warp b and is, as will be seen from Figs. 2 and 3, also utilised to maintain smoothness or compactness on the back of the fabric, this being achieved by causing it to float on the back of the fabric. The back weft e is interwoven with the-back warp b in this instance in plain weave though any other desired weave may be employed, and is also interwoven with the face warp a as indicated at e', e', in Figs. 2 and 3, to assist in binding the lower floats c2 of the face weft c firmly between the face and back warps.

In the process of finishing the fabric the lower floats c2 of the face weft, together with the whole of the face and back warps and the whole of the centre and back wefts, become compacted to form what may be termed the base fabric, whilst the upper float c of the face weft become broken in the raising portion of the process, as indicated in Fig. 3, and their component fibres then spread over the face of the base fabric. By cropping or shearing of the fabric, subsequent to raising, the pile is levelled and, by being shortened to the desired extent, can be caused to indicate with more or less clarity the weave design of the face of the fabric.

The two warps a and b and the centre and back wefts d and e are preferably composed of worsted and the face weft c of a two-ply or a three-ply woollen yarn. For a lower quality fabric one or both of the warps and either or both of the centre and back wefts may be composed of cotton or other non-wool material or of a mixture of wool and non-wool material, and for a fabric of light weight the front or face weft may consist of a suitable-ply worsted yarn.

Whilst the construction described above is the one I prefer to adopt, certain modifications are possible which, whilst being more or less obvious to those skilled inthe art of fabric design, do not affect materially the resulting fabric.

In Fig. 6 one of such modifications is shown. In this instance, instead of the face weft c being used entirely to interweave with the face warp a it is interwoven at intervals, as indicated at f, along with the back warp b. In this-modification the centre part d, instead of being used as in the construction rst described, as a tie thread to bind the two warps together, is interwoven solely with the face warp a. It will also be observed that the interweaving of the wefts e, e, hasalso been modified in order to give increased bind between the two warps. This modification of the use of the wefts e may or may not be employecLas desired.

In Fig. 'l a modification is shown in which the face weft is interwoven with both the face and back warps whilst the centre weft and back wefts are interwoven with both face and back warps as in the construction first described.

In Fig. 8 another modification is shown in which the wefts c, c, and d are interwoven solely with the warp threads a, one of the wefts e is interwoven solely with the warp threads b and the other weft e is interwoven with the warp threads b and with certain of the warp threads a; thus serving to bind the two warps together. This construction provides in effect three fabric layers, one constituted by the wefts c and some of the warp threads a, a second constituted by the weft d and the remainder of the warp threads zia-and a third constituted by the wefts e, e, and the warp threadsb.. We are thus ena-bled to employ quite distinct colours for the face and back of the fabric.

It will be understood, of course, by those skilled in the art of weaving that what I have referred to as two distinct warps maylbe carried` by one and the same beam, though in some cases, such, for instance, as that of the construction shown in Fig. 8, it will be necessary or desirable to have the warp threads a and b on separate beams owing to the difference in the rate at which they are used up. i

The phrase interwoven at least mainly as used in the following claims is intended to define threads which are interwoven wholly or mainly` with each other.

Similarly, the phrase employed at least mainly as atie thread is intended to define a fabric construction in which thread is employed wholly or mainly as a tie thread.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

1. A woven pile fabric consisting of two warps and three wefts, one of the latter being interwoven at least mainly with one of the warps to form substantially one face ofthe fabric, a second. being interwoven at leasti. mainly with the other warp to form substantially the other face of the fabric, and the third beingemployed at least mainly as a tie thread tol bind the two warps together. i l

`2. A woven pile fabric consisting of two warps and three wefts, one of the latter.` being inter@ woven mainly with one of the warps to form the face of the fabric and also at intervals with the other warp, a second weft being interwoven at least mainly with the said other warp to form the back of the fabric and the third weft being employed at least mainly as a tie thread to bind the two warps together.

3. A woven pile fabric consisting of two warps and three wefts, one of the wefts being interw-oven mainly with one of the warps to form the face of the fabric and also at intervals with the other warp, a second weft being interwoven at least mainly with the said other warp to form the back of the fabric and the third weft being interwoven solely with the warp which is utilised to form the face of the fabric.

4. A woven pile fabric consisting of two warps and three wefts, one of the wefts being interwoven at least mainly with one of the warps to form the face of the fabric, a second weft being employed at least mainly as a tie thread to bind the two warps together and the third weft being interwoven partly with the warp employed to make the face of the fabric but being mainly intere woven with the other warp to form the back of the fabric.

5. A woven pile fabric consisting of two warps and three wefts, two of said wefts being interwoven only with one of the warps and one of them forming with part of said warp the face of 'the fabric, whilst the third weft ls interwoven mainly with the other warp to form the back of the fabric but is utilised also to bind the two warps together.

6. A weft pile fabric consisting of two warps and three wefts, the first of said wefts being interwoven at least mainly with the first of said warps so as to form the front of said pile fabric and being broken at points spaced from each other so as to form the fabric piles; ythe second of said wefts being interwoven at least mainly with the second of said warps so as to form the back of said pile fabric; and the third of 4said wefts being employed at least mainly as a tie thread to bind said two warps together,

'7. A weft pile fabric consistingA of two warps and three wefts, the first of said wefts being interwoven mainly with the first of said warps so as to form the front of said pile fabric and also at intervals with the second of said warps and being broken at points spaced from each other so as to form the fabric piles; the second of said' Wefts being interwoven at least mainly with the second of said warps so as to form the back of said pile fabric; andthe third of said wefts being employed at least mainly as a tie thread to bind said two warps together.

8. A weft pile fabric consisting of two warps and three wefts, the first of said wefts being interwoven at least mainly with the first of said warps so as to form the front of said pile fabric and being broken at points spaced from each other so as to form the fabric piles; the second of said wefts being interwoven mainly with the second of said warps and also at intervals with the first of said warps so as to form the back of said pile fab-A ric; and the third of said wefts being employed as a tie thread to bind said two warps together;

9. Aweft pile fabric consisting of two warps and three wefts, the iirst of said wefts being in-v terwoven mainly with the rst of said warps so` so as" to -f'orm the fabricH piles; the second of said'v wefts being interwoven mainly with the second of said Warps and also at intervals with the first of said Warps so as to form the back of said pile fabric and the third of said Wefts being employe-' as a tie thread to bind said two Warps together.

DAVID M. COOPER.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date Re. 10,743 Crompton Ju1y 6, 1886 363,366 Crompton May 24, 1887 642,971 Fish Feb. 6, 1900 OTHER REFERENCES Advanced Textile Design, by William Watson, Second edition, pages 68, 92, 93, 95 and 96. 

